Bow suspension system

ABSTRACT

A suspension system is provided for dampening vibrational energy and noise in an archery bow. The suspension system includes an axle shaft. A rotating member is rotatably coupled to the axle shaft and defines a string groove. A string partially extends along the string groove. The string has an over molded portion contacting the string groove for decoupling the string from the string groove to dampen vibrational energy and noise generated during each shot of the archery bow.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims the benefit of and priority to U.S. patent application Ser. No. 10/361,333, filed on Feb. 10, 2003 and entitled “Bow Suspension System”, which claims priority to and the benefit of U.S. Provisional Application Ser. No. 60/355,574, filed Feb. 8, 2002; U.S. Provisional Application Ser. No. 60/355,582, filed Feb. 8, 2002; U.S. Provisional Application Ser. No. 60/355,583, filed Feb. 8, 2002; U.S. Provisional Application Ser. No. 60/418,092, filed Oct. 11, 2002; U.S. Provisional Application Ser. No. 60/418,098, filed Oct. 11, 2002; U.S. Provisional Application Ser. No. 60/425,899, filed Nov. 13, 2002; and U.S. Provisional Application Ser. No. 60/425,960, filed Nov. 13, 2002.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to an archery bow. More particularly, the invention relates to a suspension system for dampening vibrational energy and noise in an archery bow.

2. Description of the Related Art

Archery bows are typically utilized by individuals participating in hunting or recreational archery. In each of these activities, the ability to control the exact location to which the arrow is shot is essential. At the same time, the drawing back of the string and subsequent release creates vibrational energy throughout the bow, especially in the strings and the limbs. This vibrational energy substantially interferes with one's ability to control the bow. Thus, a system that reduces vibrational energy is a highly desirable feature for a bow.

Various systems have been developed in an attempt to reduce or eliminate vibrations throughout a compound bow. For example, U.S. Pat. No. 6,415,780 to Proctor is directed to a bearing system for a compound bow. The bearing system includes a sealed ball bearing assembly and a bearing support element. A cam is mounted along an axle. The axle is supported on opposite sides of the cam by the ball bearing assembly. The ball bearing assemblies are received in bores formed in limb tip overlays. The limb tip overlays are secured to limb tips by an adhesive. Alternatively, a hole in the limb blank may be created to support the ball bearing assemblies. The ball bearing assemblies reduce rotational friction and enhance lateral stability of the cam.

In addition, Untied States Patent Application Publication Number 2002/0166550 discloses an archery bow cam including a dead blow assembly fitted within a coil spring. The dead blow assembly, which includes a dead blow element and two damping elements, dampens cam vibrations at the end of a bow shot.

SUMMARY OF THE INVENTION

According to one aspect of the invention, a suspension system is provided for dampening vibrational energy and noise in an archery bow. The suspension system includes an axle shaft. A rotating member is rotatably coupled to the axle shaft and defines a string groove. A string partially extends along the string groove. The string has an over molded portion contacting the string groove for decoupling the string from the string groove to dampen vibrational energy and noise generated during each shot of the archery bow.

BRIEF DESCRIPTION OF THE DRAWINGS

Advantages of the present invention will be readily appreciated as the same becomes better understood by reference to the following detailed description when considered in connection with the accompanying drawings wherein:

FIG. 1 is a perspective view of a bow;

FIG. 2 is a fragmentary perspective view of the bow including a suspension system according to the invention;

FIG. 3 is a cross-sectional view taken along line 3-3 in FIG. 2;

FIG. 4 is a perspective view of a limb including an axle clearance hole extending therethrough;

FIG. 5 is an exploded perspective view of an interlocking hub, a ball bearing, a dampening material for positioning within the limb;

FIG. 6 is a perspective view of the limb having the interlocking hub and the ball bearing positioned within a recessed portion;

FIG. 7 is a perspective view of the limb showing a spacer covering the ball bearing;

FIG. 8 is a cross-sectional view taken along line 8-8 of FIG. 7;

FIG. 9 is an exploded perspective view of the suspension system according to the invention;

FIG. 10 is a sectional view of a ball bearing having a dampening material molded thereto;

FIG. 11 is an exploded perspective view of the ball bearing and the dampening material;

FIG. 12 is a perspective view of an axle shaft of the suspension system;

FIG. 13 is a perspective view of the axle shaft including the ball bearing with the dampening material molded thereto;

FIG. 14 is a partially cut away view of the bow having pulleys mounted along the axle shaft;

FIG. 15 is an exploded perspective view of the pulley including a two-part outer bushing and a two-part inner bushing;

FIG. 16 is a sectional view of the pulley;

FIG. 17 is an exploded perspective view of the pulley including one-piece outer and inner bushings;

FIG. 18 is a sectional view of the pulley of FIG. 17;

FIG. 19 is an exploded perspective view of the pulley including a ball bearing;

FIG. 20 is a perspective view of an elastomeric member;

FIG. 21 is an exploded perspective view of a rotating member, a plurality of string post hookups located on the rotating member, and elastomeric members;

FIG. 22 is a perspective view of the elastomeric member coupled to one of the string post hookups;

FIG. 23 is an exploded perspective view of an outer ring formed from a dampening material and a wheel;

FIG. 24 is a perspective view of the outer ring molded to the wheel;

FIG. 25 is a cross-sectional view taken along line 25-25 of FIG. 24;

FIG. 26 is an exploded perspective view of the outer ring for stretching around the cam;

FIG. 27 is a perspective view of the rotating member and the outer ring coupled to the string post hookups;

FIG. 28 is an exploded perspective view of a bushing assembly;

FIG. 29 is a perspective view of the bushing assembly mounted along the axle shaft within the cam;

FIG. 30 is a sectional view of the cam including two of the bushing assemblies housed therewithin;

FIG. 31 is a perspective view of the bushing assembly positioned within an axle clearance hole of the limb;

FIG. 32 is an isolated perspective view of a string shock absorber assembly interconnecting first and second strings;

FIG. 33 is an exploded perspective view of the string shock absorber assembly;

FIG. 34 is a cut away view of the shock absorber assembly;

FIG. 35 is a perspective view of a string end connector interconnecting first and second strings;

FIG. 36 is a cut away view of the wheel including an internal suspension assembly;

FIG. 37 is a cross-sectional view taken along line 37-37 in FIG. 36;

FIG. 38 is a partially exploded view of the cross-sectional view in FIG. 37;

FIG. 39 is an isolated view of a dampening dowel of the internal suspension assembly;

FIG. 40 is a perspective view of another embodiment of the invention including a string having a plurality of over molded portions;

FIG. 41 is a front, elevational view of a mold for over molding the string with the plurality of over molded portions;

FIG. 42 is a perspective view of the string positioned inside the mold;

FIG. 43 is a fragmentary, perspective view of the string installed along a cam of an archery bow wherein one of the over molded portions is disposed between the string and a string groove of the cam;

FIG. 44 is a perspective view of another embodiment of the invention including a wheel having a body;

FIG. 45 is a perspective view of the wheel including an over molding molded to the body;

FIG. 46 is a cross-sectional view taken along lines 46-46 of FIG. 45 including a string groove of the wheel covered by the over molding;

FIG. 47 is a perspective view of another embodiment of the invention including a cam having a body;

FIG. 48 is a side view of the cam including an over molding secured to the body;

FIG. 49 is a cross-sectional view taken along lines 49-49 in FIG. 48 including a string groove of the cam covered by the over molding;

FIG. 50 is a fragmentary, perspective view of one limb of an archery bow including a fork at a distal end;

FIG. 51 is a partially exploded, fragmentary perspective view of the limb fork including a pair of spaced apart housings for receiving an interlocking hub;

FIG. 52 is a fragmentary, perspective view of the limb fork including a suspension device over molded onto outboard and inboard surfaces of the housing for interlocking engagement with the interlocking hub;

FIG. 53 is a cross-sectional view taken along lines 53-53 in FIG. 52;

FIG. 54 is a perspective view of a billet, including at least one billet portion secured thereto, utilized for machining a limb;

FIG. 55 is a perspective view of the billet, including the at least one billet portion., with the machined limb formed therefrom shown in phantom;

FIG. 56 is an exploded, perspective view of the attachment between a limb tip housing and a limb tip according to another embodiment of the invention;

FIG. 57 is an exploded, perspective view of the limb tip housing including an interlocking hub retainer retaining an interlocking hub in place;

FIG. 58 is a perspective view of another embodiment of the invention including a suspension device disposed between a limb tip housing and a limb;

FIG. 59 is an exploded, perspective view of the suspension device for positioning between the limb tip housing and the limb;

FIG. 60 is a perspective view of a riser including a suspension housing according to another embodiment of the invention;

FIG. 61 is a fragmentary, perspective view of an archery bow including a suspension device disposed within the suspension housing for decoupling the riser from a cable guard;

FIG. 62 is a fragmentary, rear perspective view of an archery bow including a suspension device according to another embodiment of the invention positioned inside a cable guard slide;

FIG. 63 is a perspective view of the cable guard slide including the suspension device decoupling the cable guard slide from the cable guard arm;

FIG. 64 is a fragmentary, perspective view of an archery bow according to another embodiment of the invention including a cable guard arm;

FIG. 65 is a an exploded, perspective view of the cable guard arm including a suspension device disposed between elongated inner and outer cores;

FIG. 66 is a fragmentary, perspective view of an archery bow according to another embodiment of the invention including a roller arm extending out from a riser;

FIG. 67 is a exploded, perspective view of the roller arm including a pulley disposed between a pair of suspension devices;

FIG. 68 is a perspective view of a suspension device decoupling a limb from an axle shaft of an archery bow according to another embodiment of the invention;

FIG. 69 is a cross-sectional view of the suspension device decoupling the limb from the axle shaft;

FIG. 70 is a perspective view of a limb rotatably mounted along an axle shaft adjacent a suspension device according to another embodiment of the invention;

FIG. 71 is a cross-sectional view of the limb including a clearance hole for allowing relative shifting of a ; and

FIG. 72 is a fragmentary, perspective view of an archery bow according to another embodiment of the invention including a suspension device disposed between upper and lower limb portions.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENT

Referring to FIG. 1, an archery bow, generally shown at 10, includes a handle or riser 12, a grip 14, and limb pockets 16, 18 secured to the riser 12. Although a compound bow is shown in FIG. 1, it is contemplated that the following description is equally applicable to other bows including, but not limited to, cross bows and recurve bows. The bow 10 includes a pair of upper limbs 20, 22 extending between the limb pocket 16 and a rotating member or wheel 24. A pair of lower limbs 26, 28 extends between the limb pocket 18 and a rotating member or cam 30. The wheel 24 and the cam 30 are each rotatably mounted on a respective axle shaft 32, 34. The axle shaft 32 extends between the upper limbs 20, 22, and the axle shaft 34 extends between the lower limbs 26, 28.

A string 36 extends from a distal end 38 of the upper limbs 20, 22 to a distal end 40 of the lower limbs 26, 28. More specifically, one end of the string 36 extends around the wheel 24 and the other end of the string 36 extends around the cam 30. A drawstring portion 35 of the string 36 is drawn away from the riser 10, which causes the distal ends 36, 40 of the limbs 20, 22, 26, 28 to flex inwardly. As a result, energy is stored within the limbs 20, 22, 26, 28. This stored energy is released when the drawstring portion 35 of the string 36 is released to shoot an arrow 33. A regular harness 42 and a split harness 44 also extend between the wheel 24 and the cam 30. A cable guard rod 46 extends between the riser 12 and the string 36.

Referring to FIGS. 2 and 3, a suspension system, generally shown at 46, for the bow 10 includes one of the upper limbs 22, the axle shaft 32, a bushing or ball bearing 48 mounted along the axle shaft 32, and a dampening member 50 extending outwardly from the bushing 48 and positioned between the bushing 48 and the upper limb 22. It will be appreciated that although the suspension system 46 is shown with regards to one of the upper limbs 22, the suspension system 46 applies equally to the other upper limb 20 and the lower limbs 26, 28. The suspension system 46 is also rigid enough to support the bow 10. As a result, the suspension system 46 is able to store kinetic energy, to dissipate shock, and to increase bow speed.

The dampening member 50 is an elastomeric material including thermoplastic elastomers. In a preferred embodiment, the dampening member 50 is formed from urethane. The dampening member 50 may also be a spring, a spring washer, or an incompressible fluid. The dampening member 50 decouples the axle shaft 32 from the upper limb 22 so that the axle shaft 32 floats freely relative thereto. In addition, the dampening member 50 absorbs vibrational energy exerted through the axle shaft 32.

Referring to FIG. 4, the limb 22 includes an axle clearance hole 52 extending axially therethrough at the distal end 38. The axle clearance hole 52 defines a recessed portion 54 having a flat seating surface 56. The axle shaft 32 extends through the axle clearance hole 52, including the recessed portion 54 thereof, for mounting the limb 22 along the axle shaft 32, as shown in FIG. 3.

The placement of the dampening member 50 and the ball bearing 48 within the recessed portion 54 can be accomplished in different ways. Referring to FIGS. 5 through 8, an interlocking hub 58 includes an inner cavity 60 and an outer groove 62. The ball bearing 48 is inserted into the inner cavity 60. A spacer 64 is then secured to the interlocking hub 58 to cover the ball bearing 48. The interlocking hub 58 is inserted into the recessed portion 54. Finally, the elastomeric material is injected into the recessed portion 54. The elastomeric material flows through hub apertures 59 and into the outer groove 62 to form the dampening member 50. The outer groove 62 interlocks the dampening member 50 to retain the dampening member 50 within the recessed portion 54. In addition, the dampening member 50 is molded to the limb 22.

Referring to FIGS. 9 through 11, the ball bearing 48 and the dampening member 50 are molded together away from the upper limb 22 and then press fit into the recessed portion 54 of the upper limb 22. A plurality of axle spacers 66 are mounted along the axle shaft 32 and are positioned between the rotating member 24 and each of the upper limbs 20, 22.

Referring to FIGS. 12 and 13, the axle shaft 32 includes circular segments 70, 72 and keyed segments 74 extending therebetween. A step 75 is located along the keyed segment 74. One of the rotating members 24, 30 is mounted along the keyed segment 74 of the axle shaft 32. The rotating member 24, 30 has an axle hole 100, shown in FIG. 3, that is shaped to complement the keyed segment 74. This allows the string 36, which extends around the rotating member 24, 30, to be closer to the axle shaft 32 to allow let off. The ball bearings 48 are mounted along the circular segments 70, 72 of the axle shaft 32, also shown in FIG. 3. The rotating member 24, 30 is mounted along the non-circular segment 74.

Referring to FIGS. 14 through 20, a pulley 76 is mounted along the axle shaft 32 and disposed adjacent the limb 20. Each pulley 76 receives the split harness 44 therealong. The pulley 76 includes a two-piece reinforcing ring or outer bushing 78, a two-piece inner bushing 80, and the dampening member 50 therebetween. It will be appreciated that although the outer bushing 78 and the inner bushing 80 are shown as being two-piece components, one or both of the outer bushing 78 and the inner bushing 80 can be formed as a one-piece component. The outer bushing provides structural support for the dampening member 50. The outer 78 and inner 80 bushings define an interlocking passage 82 that lockingly engages the dampening member 50. The dampening member 50 is thus bonded to both the outer 78 and inner 80 bushings. The pulley 76 allows the axle shaft 32 to rotate freely thereabout with little or no friction.

Referring specifically to FIGS. 17 and 18, the pulley 76 includes the dampening member 50 positioned between one-piece outer 77 and inner bushings 79 without an interlocking passage formed therebetween. Referring to FIG. 19, the pulley 76 includes the ball bearing 48 and the reinforcing ring 78 retaining the dampening member 50 therebetween.

Referring to FIG. 20, a elastomeric member 81 is formed completely from an elastomeric material, preferably urethane. The elastomeric member 81 is generally ring-shaped. Referring to FIGS. 21 and 22, a plurality of string post hookups 84 is located along an outer surface 86 of the cam 30. The string 36 extends around the cam 30 and is secured into place by the string post hookups 84. The elastomeric member 81 is mounted to the one or more of the string post hookups 84 to dampen vibrational energy in the string 36. It will be appreciated that the pulley configurations set forth above and shown in FIGS. 15 through 19 are equally applicable to the string post hookups 84.

Referring to FIGS. 23 through 26, an outer ring 88 extends all along an outer periphery of the wheel 24. The wheel 24, which is typically formed from a metal such as aluminum, provides structural support for the outer ring 88, which is formed from an elastomeric material. The outer ring 88 includes an interlocking rim 90 interconnected to a rotating member string groove 92 for retaining the outer ring 88 to the wheel 24. The outer ring 88 further includes an outer string groove 94 for receiving the string 36. The positioning of the outer ring 88 between the wheel 24 and the string 36 decouples the wheel 24 and the string 34, and dampens vibrational energy that is exerted upon the wheel 24 when the string 36 is released to shoot the bow 10.

The outer ring 88 is secured to the wheel 24 by various methods including molding, bonding, stretching, and snapping into place. The assembly method chosen depends in large part upon the shape of the rotating member 24, 30. For example, when the rotating member is the cam 30, as shown in FIG. 26, it is preferable to stretch the outer ring 88 into place.

Referring to FIG. 27, the outer ring 88 is adapted to fit around an outer periphery of the string post hookup 84 of the cam 30. The string post hookup 84 provides structural support for the outer ring 88. The outer ring 88 may be secured to the string post hookup 84 by various methods including molding, bonding, stretching, and snapping into place.

Referring to FIGS. 28 through 31, a bushing suspension assembly, generally shown at 96, includes a bushing member 97 and a dampening sleeve 98. The bushing member 97 is formed from metal, plastic, or an elastomeric material, while the dampening sleeve 98 is formed from an elastomeric material. The elastomeric material includes, but is not limited to, urethane and polyurethane. Referring specifically to FIGS. 29 and 30, the bushing suspension assembly 96 is positioned within the axle hole 100 of the cam 30. Referring to FIG. 31, the bushing suspension assembly 96 is positioned within the axle clearance hole 52 of the limb 22. The bushing member 97 may be replaced with the ball bearing 48.

Referring to FIGS. 32 through 34, a string shock absorber assembly, generally shown at 102, interconnects a first string 104 extending from the wheel 24 and a second string 106 extending from the cam 30, as is also shown in FIG. 1. The first string 104 extends from one of the rotating members 24, 30 while the second string 106 extends from the other of the rotating members 24, 30. The string shock absorber assembly 102 includes an elongated hollow string shock absorber 108 extending between ends 110, 112. The string shock absorber 108 is formed from an elastomeric material, such as urethane or polyurethane, so as to be able to be stretched or extended from its original length in order to store and dissipate energy. The string shock absorber assembly 102 dampens vibrational energy created in the first 104 and second 106 strings before that vibrational energy is transferred to the wheel 24 and the cam 30.

A string hookup connector 114 is mounted within the string shock absorber 108 at each of its ends 110, 112. The string hookup connector 114 includes an internal channel 116 for receiving the one of the first 104 and second 106 strings. Each internal channel 116 has a tapered end 115 for retaining one of the first 104 and second 106 strings therein. Each string hookup connector 114 is formed from metal, preferably aluminum.

The string shock absorber assembly 102 is assembled by first inserting the first string 104 one of the string hookup connectors 114 and the second string 106 into another of the string hookup connectors 114. The string hookup connectors 114, with the first 104 and second 106 strings secured therewithin, are then placed in a mold, where the string shock absorber 108 is formed so as to encapsulate the string hookup connectors 114. During the molding process, string ends 118, 120, which extend out of the string hookup connectors 114, are molded to the string shock absorber 108.

Referring to FIG. 35, the string hookup connector 114 is adapted to interconnect the ends 110, 112 of the respective first 104 and second 106 strings. The string hookup connecter 114 is molded from an elastomeric material, such as urethane or polyurethane.

Referring to FIGS. 36 through 39, an internal suspension assembly 122 for the wheel 24, having an internal chamber 124 and an outer periphery 126, includes a inner housing 128, which is preferably formed from metal, generally positioned within the internal chamber 124. The ball bearing 48 is housed within the hub 128, and a plurality of dampening dowels 130 extend out from the hub 128 to the outer periphery 126 of the rotating member 24. Retainer caps 132 secure the dampening dowels 130 to the wheel 24. The dampening dowels 130 are formed from an elastomeric material including, but not limited to, urethane and polyurethane. Each of the dampening dowels 130 includes a male locking dowel base 134 and a female locking dowel base 136. The dampening dowels 130 are free to actuate within the internal chamber 124 to dampen vibrational energy in the wheel 24.

It is intended that all of the elements described above and shown in the FIGS. 1 through 39 are incorporated into a single bow to form a complete suspension system. The suspension system retains energy in the source, that is, the string 36 rather than throughout the bow 10. This retained energy is transferred to the arrow 33.

Referring to FIGS. 40 through 42, according to another embodiment of the invention, the string 36 includes at least one over molded portion 200 for decoupling the string 36 from a string groove 201 of either the cam 30, as shown in FIG. 43, or the wheel 24. A method for over molding the string 36 utilizes a mold, generally indicated at 202, including upper 204 and lower 206 mold halves. For exemplary purposes, the mold 202 may be an injection moldable mold, a cast mold, or a hand lay-up mold. The upper 204 and lower 206 mold halves define a mold cavity 208 therebetween. At least one tensioner or air cylinder 210 may be positioned adjacent at least one end of the mold 202. The mold 202 also includes a plurality of spaced apart injection ports 212.

The method of over molding the string 36 begins with the step of placing the string 36 inside the mold 202 within the mold cavity 208. A string loop 214 is located at each end of the string 36. Each string loop 214 is secured to one of the tensioners 212, which holds the string 36 in tension during the over molding process. It is, however, appreciated that the tension in the string 36 may be achieved by any of various methods known to those skilled in the art. Once the string 36 is in tension, the mold 202 is closed and a molding material enters the mold cavity 208 via the plurality of injection ports 212. In a preferred embodiment, the molding material is an elastomeric material, such as polyurethane. It is, however, appreciated that the molding material may be any of various materials including, but not limited to, a foam or a gel.

Once the elastomeric material is cured, the spaced apart over molded portions 200 are formed along the string 36. The string 36 is then removed from the mold 202 and installed on the archery bow 10, as shown in FIG. 43. Once installed, one of the over molded portions 200 contacts the string groove 201 of the cam 30 and another of the over molded portions 200 contacts the string groove 201 of the wheel 24 (not shown). Thus, the over molded portions 200, which are each formed from elastomeric material, decouple the string 36 from the string groove 201 of the cam 30 and the wheel 24. As a result, vibrational energy generated within the string 36 during each shot of the archery bow 10 is dampened and cannot be transferred to a limb 230 of the archery bow 10. Further, the over molded portions 200 of the string 36 protect the string 36 from de-serving issues, which in turn prolongs the life of the string 36.

It is contemplated that the exact configuration of the string 36 having the over molded portions 200 may vary. It is also contemplated that in the method for over molding the string 36, as set forth above, the particular shape of the over molded portions 200 can be controlled. As a result, the string 36 (or other archery bow component) may have different shapes in order to optimize dampening performance.

It is further contemplated that the above-mentioned method for over molding may be utilized to over mold other archery bow components including, but not limited to, the wheel 24, shown in FIGS. 44 through 46, and the cam 30, shown in FIGS. 47 through 49. Referring to FIGS. 44 through 46, the wheel 24 includes a body 216, formed from a metal or plastic, defining a plurality of apertures 218 and a plurality of interlocking flow ports 220. The body 216 is placed inside the mold 202, where the molding material is introduced. The molding material flows through the plurality of interlocking flow ports 220 such that once the molding material is cured, the wheel 24 includes an over molding 222 that is locked into place. The over molding 222 extends over the string groove 215 such that when the wheel 24 is installed on the archery bow 10, the over molding 222 decouples the string 36 from the wheel 24 to dampen vibrations generated during each shot of the archery bow 10.

Referring to FIGS. 47 through 49, the cam 30 includes a body 224, which is formed from metal or a composite material, defining a plurality of interlocking ports 226. The body 224 is placed in the mold 202, where the molding material is introduced. The molding material flows through the plurality of interlocking ports 226 such that once the molding material is cured, the cam 30 includes an over molding 222 extending along the string groove 201 and along parts of the body 224. The over molding 222 includes acoustical turbines as well as acoustical waffles each formed from an elastomeric material. Once the molding material is cured, the over molding 222 is interlocked with the plurality of interlocking ports 226.

Referring to FIGS. 50 and 51, according to another embodiment of the invention, each limb 230 of the archery bow 10 includes a fork, generally indicated at 232, at a distal end adjacent the wheel 24 (or cam 30). The fork 232 includes a pair of spaced apart limb tips 234, 236 each having a housing 238. Preferably, the pair of spaced apart limb tips 234, 236 is integrally formed with the rest of the limb 230. Each housing 238 includes inboard 240 and outboard 242 surfaces defining an interior 244 therebetween. Multiple cutouts, including a central aperture 246, an access hole 248, and spaced apart trusses 250 are formed along each of the inboard 240 and outboard 242 surfaces and may be in any of various shapes. An interlocking hub 252 is disposed within the interior 244 and is aligned with the central aperture 246. Each interlocking hub 252 includes a channel 254. Each interlocking hub 252 also includes an axle hole 256 for receiving an axle shaft (not shown) therethrough.

Referring to FIGS. 52 and 53, a suspension device 258 is over molded onto each housing 238 for decoupling the string and harness load from the riser 12. The suspension device 258 is preferably formed from an elastomeric material, such as polyurethane. It is, however, appreciated that although the suspension device 258 has been disclosed as an elastomeric material, the suspension device 258 may be a rotary actuator, a linear actuator, a coil spring, or a leaf spring.

The elastomeric material flows through the access hole 248 and the spaced apart trusses 250 to fill the interior 244 of each housing 238 and the channel 254 of the interlocking hub 252 for interlocking engagement therewith when cured. The suspension device 258 also covers the inboard 240 and outboard 242 surfaces of each housing 238, leaving only the axle hole 256 accessible. Once the interlocking hub 252 is in such interlocking engagement with the suspension device 258, the interlocking hub 252 is not able to move sideways, which in turn prevents any wheel and/or cam lean.

Referring to FIGS. 54 and 55, a method for manufacturing the limb 230 including the suspension device 258 over molded onto each of the housings 238 begins with the step of providing a billet or blank, generally indicated at 260, for use as a core member. The billet 260, which has a length L₁ extending between opposing first 262 and second 264 ends, may be formed from any of numerous processes including, but not limited to, protrusion, resin transfer molding, and compression molding. The material utilized for forming the billet 260 is preferably a composite. Other materials including, but not limited to, fiberglass, Kevlar®, spectra, and carbon may also be used to form the billet 260. At least one billet portion 266 is bonded, glued, or otherwise adhered to the billet 260 at the first end 262 thereof. The billet portion 266 may be formed from the same material as the billet or from a material different from the billet 260. The particular number of billet portions 266 bonded to the billet 260 is that which is required to form a predetermined height H₁. Moreover, the particular bonding location of the billet portions 266 is important for maintaining structural integrity in the finished limb 230. Further, the core has a constant cross-section throughout, which maintains the rigidity of the part. The billet 260 and billet portions 266 are placed under pressure at a controlled temperature, preferably using a press. The limb 230 is then machined to the one-piece configuration, shown in FIG. 55, including the limb fork 232 and the pair of spaced apart housings 238.

One of the interlocking hubs 252 is then inserted through the access hole 248 into the interior 244 of each housing 238. The limb 230 is placed in a mold, in which the interlocking hubs 252 are centered relative to the respective housings 238. An elastomeric material, preferably polyurethane, is then over molded onto each housing 238 to form the suspension device 258 creating a mechanical interlocking system and a chemical bond for retaining the interlocking hubs 252 in place within the interior 244 of the respective housings 238. The suspension device 258 both within the interior 244 of the housing 238 and along the inboard 240 and outboard 242 surfaces thereof maintain the interlocking hub 252 in place. Once the interlocking hub 252 is retained as such, the interlocking hub 252 cannot move sideways. As a result, no wheel or cam lean occurs. In addition, the interlocking hub 252 can translate in one direction and the direction of movement is always in the direction of the string, harness, and/or control cable loading.

Referring to FIGS. 56 and 57, according to another embodiment of the invention, the limb 230 is a two-piece component including a pair of limb tip housings 270 fixedly secured to each limb tip 234, 236. Each limb tip housing 270 defines an elongated slot 272 at one end and a cavity 274 at an opposing end. The elongated slot 272 receives one of the limb tips 234, 236. At least one bolt or fastener 276 is utilized to fixedly secure each limb tip housing 270 to one of the limb tips 234, 236.

The cavity 274 of each limb tip housing 270 is counter-bored and receives an interlocking hub retainer 278. The interlocking hub retainer 278 retains the interlocking hub 252 within the cavity 274 and prevents any sideways movement of the interlocking hub 252. A suspension device 280 is disposed within the cavity 272 for decoupling the string and cable harness load from the riser 12. The suspension device 280 is formed from an elastomeric material, preferably polyurethane.

In a method for manufacturing the limb 230 according to the present embodiment, the interlocking hub retainer 278 and the interlocking hub 252 are placed inside the cavity 274 of one of the limb tip housings 270. The limb tip housing 270 is then placed inside a mold. The suspension device 280 is over molded onto the cavity 274 of the limb tip housing 270, where upon curing it interlockingly engages the interlocking hub 252. Finally, the limb tip housing 270 is fixedly secured to one of the limb tips 234, 236 via the bolts 276.

Referring to FIGS. 58 and 59, according to another embodiment of the invention, a suspension device 282 is disposed between the elongated slot 272 of the limb tip housing 270 and a main limb body 284 for decoupling the limb tip housing 270 from a main limb body 284. The limb tip housing 270 is fixedly secured to the main limb body 284 via a plurality of fasteners (not shown). The suspension device 282, which is generally U-shaped, dampens out vibrations generated by the string 36 and cable and harness system 283 during each shot of the archery bow 10. It is appreciated that the particular shape of the suspension device 282 may vary. The suspension device 282 may be formed from any of numerous dampening materials. In a preferred embodiment, the suspension device 282 is formed from an elastomeric material.

Referring to FIGS. 60 and 61, according to another embodiment of the invention, the riser 12 includes a suspension housing 286 defining a cavity 288. In a preferred embodiment, the suspension housing 286 is generally cylindrical. It is, however, appreciated that the particular shape of the suspension housing 286 may vary. The suspension housing 286 includes a plurality of interlocking openings 290 therealong. One end of a cable guard arm 292 is disposed within the cavity 288. A suspension device 294 is disposed within the suspension housing 286 between the suspension housing 286 and the cable guard 292 for decoupling the cable guard 292 from the riser 12. Thus, the suspension device 294 dampens vibrational energy generated by at least one of the string 36 and the cable and harness system 283. The suspension device 294 is retained within the suspension housing 286 by a mechanical interlock achieved by the suspension device 294 extending through the plurality of interlocking openings 290. It is appreciated that the suspension device 294 may also be glued, bonded, or otherwise adhered within the suspension housing 286 formed in the riser 12.

Referring to FIGS. 62 and 63, a cable guard slide 296 is disposed along the cable guard arm 292. The cable guard slide 296 includes an elongated bore 298 for receiving the cable guard arm 292 therethrough. A bushing 300 is disposed within the elongated bore 298. A suspension device 302 is disposed within the elongated bore 298 and completely surrounds the cable guard arm 292 for decoupling the cable guard arm 292 from the cable guard slide 296.

Referring to FIGS. 64 and 65, according to another embodiment of the invention, the cable guard arm 292 includes an inner elongated core 304 and an outer elongated core 306. Each of the inner 304 and outer 306 elongated cores is formed from a solid, non-elastomeric material. A suspension device 308 is disposed between the inner 304 and outer 306 elongated cores to decouple the inner elongated core 304 from the outer elongated core 306, which in turn decouples the cable and harness system 283 from the riser 12. The suspension device 308 is preferably formed from an elastomeric material. It is, however, appreciated that the suspension device 308 may be formed from any of numerous dampening materials.

Referring to FIGS. 66 and 67, a roller or cable arm, generally indicated at 310, extends between the riser 12 and the split harness and control cable system. The cable arm 310 includes a main body portion 312 and a pair of spaced apart housings 314 extending out therefrom. Each of the spaced apart housings 314 defines a bore 316. A suspension device 318 is disposed within the bore 316 of each housing 314. Each suspension device 318 includes an aperture 320 extending therethrough. The suspension devices 318 are preferably formed from an elastomeric material. A pulley 322 is disposed between the suspension devices 318 for receiving a portion of the cable and harness system 283 therearound. The pulley 322, which is preferably formed from an elastomeric material, includes an elongated bore 324 extending therethrough. An axle shaft 326 extends through the apertures 320 and the elongated bore 322 to retain the pulley 322 in place between the suspension devices 318. The suspension devices 318 decouple the axle shaft 326 as well as the cable and harness system 283 from the cable arm 310 such that at least a portion of the load from the cable and harness system is dampened by the suspension devices 318.

Referring to FIGS. 68 and 69, according to another embodiment of the invention, a suspension device, generally indicated at 330, is disposed between the axle shaft 326 and the limb 230 in order to decouple the string 36 from the limb 230. The suspension device 330 includes a ball bearing 332 encased within a suspension housing 334. The axle shaft 326 is disposed within the ball bearing 332 and suspension housing 334 of the suspension device 330. The axle shaft 326 does not, however, reside within the limb 230. Instead, a fastener 336, such as a fastener or e-clip, secures a pulley 338 to the limb 230 adjacent the suspension housing 334. As a result, the axle shaft 326, and with the wheel 24 or the cam 30, is decoupled from the limb 230.

Referring to FIGS. 70 and 71, in an alternative embodiment, the axle shaft 326 passes through the limb 230. The limb 230 includes a clearance hole 339 to allow the axle shaft 326 to float therwithin. The suspension device 330 is also disposed along the axle shaft 326 and includes the ball bearing 332 encased within the suspension housing 334. As a result, actuation of the suspension device 330 is not restricted.

Referring to FIG. 72, in still another embodiment of the invention, each limb 230 includes an upper limb portion 340 coupled to the axle shaft 326, and a lower limb portion 342 coupled to the limb pocket 16. A rotating member, i.e., the wheel 24 or the cam 30 is disposed along the axle shaft 326. A suspension device 344 is disposed between and coupled to the upper 340 and lower 342 limb portions. The suspension device 344 is preferably formed from an elastomeric material. It is, however, appreciated that the suspension device 344 may be formed from any of numerous dampening materials. The suspension device 344 decouples the upper limb portion 340 from the lower limb portion 342 for decoupling the string load or cable and harness system load from the riser 12.

It is hereby contemplated that multiple embodiments, set forth above, may be incorporated into a single archery bow in order to provide optimal dampening of vibrational energy throughout the archery bow 10.

The invention has been described in an illustrative manner. It is to be understood that the terminology, which has been used, is intended to be in the nature of words of description rather than of limitation. Many modifications and variations of the invention are possible in light of the above teachings. Therefore, within the scope of the appended claims, the invention may be practiced other than as specifically described. 

1. A suspension system for dampening vibrational energy and noise in an archery bow, said suspension system comprising: an axle shaft; a rotating member rotatably coupled to said axle shaft and defining a string groove; and a string partially extending along said string groove, said string having an over molded portion contacting said string groove for decoupling said string from said string groove to dampen vibrational energy and noise generated during each shot of the archery bow.
 2. A suspension system for dampening vibrational energy and noise in an archery bow having a string, said suspension system comprising: an axle shaft; a rotating member rotatably coupled to said axle shaft and having a string groove; and an over molding coupled to said rotating member along said string groove for decoupling said rotating member from the string to dampen vibrational energy generated by the string.
 3. A method for over molding a string of an archery bow with a molding material via a mold, the method comprising the steps of: placing the string inside the mold; applying tension to the string; and introducing the molding material into the mold to form at least one over molded portion along the string.
 4. A method as set forth in claim 3 wherein the step of applying tension to the string occurs prior to the step of introducing the molding material into the mold to form at least one over molded portion along the string.
 5. A method for over molding a wheel, having a body including a plurality of interlocking flow ports and a string groove, with a molding material via a mold, the method comprising the steps of: placing the body inside the mold; introducing the molding material into the mold for entry inside the interlocking flow ports; and curing the molding material to form an over molding interlocked in place over the body and along the string groove.
 6. A method of over molding a cam, having a body including a plurality of interlocking ports and a string groove, with a molding material via a mold, the method comprising the steps of: placing the body inside the mold; introducing the molding material into the mold for passage within the interlocking ports; and curing the molding material to form an over molding interlocked with the string groove.
 7. An archery bow for decoupling a string and harness load from a riser, said archery bow comprising: a limb adapted to be coupled to the riser and having a fork opposite the riser, said fork defining a pair of spaced apart housings each having an interior; an interlocking hub disposed within said interior of each of said spaced apart housings; and a suspension device over molded onto said housing and interlockingly engaging said interlocking hub for decoupling at least a portion of the string and harness load from the riser.
 8. An archery bow as set forth in claim 7 wherein said suspension device is formed from an elastomeric material.
 9. An archery bow for decoupling a string and harness load from a riser, said archery bow comprising: a limb adapted to be coupled to the riser, said limb having a fork including a pair of spaced apart limb tips; a limb tip housing fixedly secured to each of said spaced apart limb tips, said limb tip housing defining a cavity; and a suspension device over molded onto each of said limb tip housings and disposed within said cavity for decoupling at least a portion of the string and harness load from the riser.
 10. An archery bow as set forth in claim 9 wherein said suspension device is formed from an elastomeric material.
 11. An archery bow as set forth in claim 10 wherein each of said limb tip housings includes an interlocking hub within said cavity in interlocking engagement with said suspension device.
 12. An archery bow as set forth in claim 11 including an interlocking hub retainer disposed within said cavity for retaining said interlocking hub in place as said suspension device is molded thereto.
 13. A method of manufacturing an archery bow suspension system, including a limb, a fork defining a pair of spaced apart housings, and a suspension device, from a billet and at least one billet portion, the method comprising the steps of: forming the limb including the fork defining the pair of spaced apart housings from the billet and the at least one billet portion; placing one of the interlocking hubs inside each of the housings; and over molding the suspension device onto each of the housings in interlocking engagement with the interlocking hub.
 14. A method as set forth in claim 13 including the step of securing the at least one billet portions to one end of the billet prior to the step of forming the limb including the fork defining the pair of spaced apart housings from the billet and at least one billet portion.
 15. A suspension system for dampening vibrational energy in an archery bow having a riser and an axle shaft, said suspension system including: a main limb body having one end operably coupled to the riser and an opposing end having at least one limb tip; at least one limb tip housing disposed along the axle shaft and coupled to said limb tip; and a suspension device disposed between said limb tip housing and said limb tip for decoupling said main limb body from said limb tip housing to dampen vibrational energy generated at the axle shaft.
 16. A suspension system for decoupling the load generated from either of a string and a cable and harness system of an archery bow, said suspension system comprising: a riser defining a suspension housing; a cable guard rod extending between said riser and the cable and harness system; and a suspension device disposed within said suspension housing for decoupling said cable guard rod from said riser for dampening vibration generated by at least one of the string and cable and harness system during each shot of the archery bow.
 17. A suspension system as set forth in claim 16 wherein said suspension housing includes a plurality of interlocking openings for interlocking engagement with said suspension device.
 18. A suspension system for decoupling the load generated from a cable and harness system of an archery bow, said suspension system comprising: a riser; a cable guard arm extending out from said riser; a cable guard slide disposed along said cable guard arm; and a suspension device disposed between said cable guard slide and said cable guard arm for decoupling said cable guard slide from said cable guard arm to dampen vibration generated at the cable and harness system.
 19. A suspension system for an archery bow having a riser and a cable and harness system, said suspension system comprising: a cable guard arm extending out from the riser and operably connected to the cable and harness system, said cable guard arm having an elongated outer core and an elongated inner core received within an elongated outer core; and a suspension device disposed between said elongated outer and inner cores for decoupling the riser from the cable and harness system to dampen vibrations generated during each shot of the archery bow.
 20. A suspension system as set forth in claim 19 wherein said suspension device is formed from an elastomeric material.
 21. A suspension system as set forth in claim 20 wherein each of said elongated outer and inner cores is formed from a solid, non-elastomeric material.
 22. A suspension system for an archery bow comprising: a riser; a roller arm extending out from said riser; a cable and harness system operably connected to said roller arm; and a suspension device secured to said roller arm and receiving said cable and harness system therealong for decoupling said cable and harness system from said riser to dampen vibration during each shot of the archery bow.
 23. A suspension system for an archery bow comprising: a riser; an axle shaft; a limb having one end operably coupled to said riser and an opposing end adjacent said axle shaft; and a suspension device disposed about said axle shaft for decoupling said limb from said axle shaft to dampen vibrations generated by said axle shaft during each shot of the archery bow.
 24. A suspension system as set forth in claim 23 wherein said suspension device includes a suspension housing disposed along said axle shaft.
 25. A suspension system as set forth in claim 24 wherein said suspension device includes a ball bearing encased within said suspension housing and disposed along said axle shaft.
 26. A suspension system for an archery bow comprising: a riser: an axle shaft; a limb having one end operably coupled to said riser and an opposite end receiving said axle shaft therethrough, said limb having a clearance hole for allowing said axle shaft to float relative to said limb; and a suspension device disposed about said axle shaft for decoupling said limb from said axle shaft to dampen vibrations generated by said axle shaft during each shot of the archery bow.
 27. A suspension system for an archery bow having a riser and a rotating member, said suspension system comprising: a lower limb portion operably coupled to the riser; an upper limb portion operably coupled to the rotating member; and a suspension device disposed between said upper and lower limb portions for decoupling the rotating member from the riser for dampening vibrational energy during each shot of the archery bow. 